Knitted wire carrier for weather seal insert support with lockstitched reinforcing wire

ABSTRACT

This invention provides a knitted wire carrier for use in constructing a (e.g.) automotive weather seal that incorporates a locking stitch formed from a relatively incompressible and expansion-resisting material that passes through at least one of the warp threads adjacent to the wire weft. In an embodiment, the locking stitch constructed from a steel (or another metal) wire that is solid or braided. In other embodiments, the locking stitch can be constructed from fiberglass, monofilament polymer or another similarly performing material. In an embodiment, the lockstitch wire is constructed from approximately 0.5-millimeter diameter steel and the wire carrier is constructed from approximately 0.5-0.91-millimeter diameter steel. The wire lockstitch can be woven through a center warp yarn that is surrounded by other knitted warp yarns along the overall weft of the wire carrier. The wire carrier is coated with an adhesive, e.g., latex to maintain the knit in place.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/854,036, entitled KNITTED WIRE CARRIER FOR WEATHER SEAL INSERTSUPPORT WITH LOCKSTITCHED REINFORCING WIRE, filed Sep. 14, 2015, whichis incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

This invention relates to wire carriers having a knitted stitching usedas backing for elastomeric weather seals in automotive and otherapplications, such as electrical cabinets where maintaining weatherimpermeability is a critical attribute.

BACKGROUND OF THE INVENTION

Knitted wire carriers are commonly used in the area of automotiveweather seals, among other uses. Generally, such carriers consist of acontinuous wire weft formed into a serpentine propeller pattern withrounded ends. The ends join together a series of approximatelypropeller-shaped or parallel weft segments (limbs) upon which aplurality of warp threads is knitted. This type of knitted wire carrieris used as a reinforcing frame for elastomeric seals that are producedby extrusion and other continuous-forming processes. Such seals areoften used in automotive and other vehicle applications.

The manufacture of extruded weather seals involves the application ofsubstantial forming pressure to the wire carrier. The warp threads inmany examples are applied in clusters or strips, all of which aredesigned to maintain the serpentine (also informally termed “zig-zag”)wire weft the appropriately spaced orientation during the formationprocess. Absent these warp threads, the wire would tend to stretch anddeform, generating an inferior or unusable finished seal product.

Wire carriers are an efficient mechanism for constructing a weatherseal. However in certain application they experience excesscompressibility or elongation—for example when the weather seal isfitted around a tight-radius corner. That is, the seal compresses orstretches and does not maintain the desired, conforming profile on thedoor, trunk, etc.

One prior art approach to reduce excess compressibility and elongationin weather seals is to reinforce with elastomeric seal element with aperforated metal (e.g. low carbon steel) strip. Such a strip 100 in anunfolded orientation is shown by way of background in FIG. 1. Thespecific geometry of the strip 100, as well as its overall width,length, thickness, are highly variable depending on the weather sealapplication and desired performance characteristics. In an embodiment,the strip 100 has an overall width SW of approximately 20-65 millimetersand a thickness (perpendicular to the page of the figure) of betweenapproximately 0.3 and 0.76 millimeters (e.g. 0.45 millimeters). Theexemplary strip 100 includes a series of regular edge slots 110, formedalong each opposing edge, having a width WS of between approximately 1and 3 millimeters, and a series of central slots 120 offset from theedge slots 110 as shown. The strip can be formed into a desired shape(e.g. folding, stretching, etc.) and molded into a weather seal. Thecompleted seal is capable of bending around sharp corners withoutsignificant puckering, wrinkling, compression or elongation.

This perforated, low carbon steel strip requires a large quantity ofsheet metal to produce (weight-per-unit-of-length) and employs involvedstamping or cutting equipment, dies, etc.

SUMMARY OF THE INVENTION

This invention overcomes the disadvantages of the prior art by providinga knitted wire carrier for use in constructing an (e.g.) automotiveweather seal that incorporates a locking stitch, commonly called a“lockstitch” formed from a relatively incompressible andexpansion-resistant material that passes through at least one of thewarp threads adjacent to the wire weft. In an embodiment, the lockstitchconstructed from a steel (or another metal) wire that is solid orbraided. In other embodiments, the lockstitch can be constructed fromfiberglass, monofilament polymer or another similarly performingmaterial. In an embodiment, the lockstitch wire is constructed fromapproximately 0.5-millimeter diameter steel and the wire carrier isconstructed from approximately 0.5-0.91-millimeter diameter steel. Thewire lockstitch can be knitted through a center warp yarn that issurrounded by other knitted warp yarns along the overall weft of thewire carrier.

In an illustrative embodiment a knitted wire carrier for use in aweather seal includes a wire weft formed in a serpentine pattern anddefining a width between alternating edge bends perpendicular to anelongated length. A plurality of knitted warp yarns extend in thedirection of the elongated length and are located at positions along thewidth of the wire weft. At least a first compression andexpansion-resisting wire is woven as a lock stitch to at least one ofthe warp yarns. Illustratively, the wire weft can comprise a steel wireand the first compression and expansion-resisting wire comprises a steelwire. More particularly, the wire weft can define a diameter of betweenapproximately 0.5 and 0.91 (more particularly, 0.09085) millimeter andthe first compression and expansion-resisting wire can define a diameterof between approximately 0.3 and 0.76 millimeter, and more a diameter ofapproximately 0.5 millimeter. Illustratively, the warp yarns can beconstructed from a polyester material, or any other acceptable materialor blend. In various embodiments, the wire carrier can be coated with anadhesive material that maintains the warp yarns in a desired position onthe wire weft, such as a latex coating. In various embodiments, a secondcompression and expansion-resisting wire can be knitted as a lockstitchto at least one of the warp yarns. This second wire is typically locatedat a spacing along the width of the wire weft from the first compressionand expansion-resisting wire. In embodiments, the first compression andexpansion-resisting wire is approximately centered along the width ofthe wire weft. In embodiments, the first and/or second compression andexpansion-resisting wire is/are constructed from a non-metallicmaterial, such as fiberglass. Illustratively, the weather seal can beapplied to a variety of moisture/weather-tight and/ormoisture/weather-resistant structures including, but not limited to,vehicles, boats, aircraft, utility cabinets, doors, electricalenclosures, etc.

In an illustrative embodiment a method for constructing wire carrierwith a knitting machine is provided. This method includes the step offeeding and forming a wire into a wire weft defining a serpentinepattern having a width between alternating edge bends perpendicular toan elongated length. Warp yarns are knitted so that they extend in thedirection of the elongated length and are locate at various spaced-apartpositions along the width of the wire weft using weaving needles in aneedle guide. In addition, at least a first compression andexpansion-resisting wire is knitted as a lock stitch to at least one ofthe warp yarns. The first compression and expansion-resisting wire isknitted by the machine with the needle bed containing a slot for a dummyneedle necessary to place the expansion-resisting wire.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention description below refers to the accompanying drawings, ofwhich:

FIG. 1 is a diagram of a perforated steel strip used to reinforce anelastomeric weather seal according to the prior art;

FIG. 2 is a diagram of a knitted wire carrier including a compressionand expansion-resisting lockstitch, located around the center of thecarrier width, for use in reinforcing an automotive weather sealaccording to an illustrative embodiment;

FIG. 3 is a perspective view of a knitting weaving needle bed showing anempty slot for placement of a wire lockstitch according to anillustrative embodiment;

FIG. 4 is a diagram of a knitted wire carrier including compression andexpansion-resisting lockstitch located on one side of the carrier widthaccording to an alternate embodiment; and

FIG. 5 is a diagram of a knitted wire carrier including a pair ofcompression and expansion-resisting lockstitches located on each side ofthe carrier width according to an alternate embodiment.

DETAILED DESCRIPTION

A segment knitted wire carrier 210 according to an embodiment of thisinvention is shown in FIG. 1. This carrier 210 consists of a serpentinebent wire 220. This wire can be constructed from a variety of deformablematerials. For example the wire 220 can be low-carbon steel, galvanizedsteel or aluminum alloy having a diameter of between approximately 0.02and 0.045 inch (approximately 0.5 millimeters to 1.14 millimeters). Incertain embodiments, the wire 220 can be coated with ananti-rust/anti-corrosion coating or plating. When manufactured, the wire220 is bent generally in a planar fashion, and is formed into acontinuous strip by a swinging, back and forth motion (for forming theweft) of a knitting machine that can be conventional in design. Thestrip has a generally constant width W between the bend apices 130 oneach opposing side. In one example, that width W is approximately 1¼-1⅝inches (31.75 to 42.54 millimeters). However, the width WW of the wirecarrier is highly variable depending, in part, upon the selectedapplication for which it is used.

The bent wire 220 essentially defines the weft, about which a series ofwarp yarns 240 are knitted. These warp yarns, as discussed above,maintain the relative shape and spacing of the bent wire segments andprovide a further substrate for elastomeric/polymeric weather sealmaterial (not shown) to adhere to the carrier 210. In this example, thewarp yarns 240 are generally specifically spaced divided into variouspatterns across the width. In this embodiment, the yarns are constructedfrom polyester with a Denier of approximately 1000 and betweenapproximately 140-300 filaments. Note that this specification for warpyarns is only exemplary and that a wide range of materials, denier andfilament counts are expressly contemplated.

By way of non-limiting example, the wire's bend apices 230 are connectedto curved wire bend segments that define a wider spread than the spreadbetween adjacent central wire segments. By having a wider spread betweenadjacent wires near the ends than in the center, the carrier defines thegeneral outline appearance of a “propeller” blade. This conventionalshape is used in part, to maintain the edge warps and near or at theapices since they must “climb over” the widened spread between segmentsto creep into the middle. Additionally, the warps are adhered to thecarrier using, for example a layer of latex that holds the warps inplace on the wire 220. The latex can be applied after the knittingprocess is completed using a spray nozzle or a dip tank.

Notably, the center warp yarn 250 locked using a lockstitch 260 thatweaves in and out of the knit. This lock stitch wire 260 isillustratively constructed from 0.02-inch (0.5 millimeter) steel wire.The diameter of the wire 260 can be highly variable (e.g. 0.3-0.76millimeter) in alternate embodiments. The wire lockstitch serves toresist both expansion and compression of the carrier when it is encasedin weather seal polymer and bent around shapes of various curvatures.That is, the lockstitch wire 260 imparts internal stiffness in thedirection of elongation of the weather seal.

The expansion and compression-resisting wire can be secured to thecarrier in various ways. In embodiments it can be spot-welded to thewire carrier. It can be separately tied and/or adhesives can beemployed. A weaving needle bed block 310 of conventional design is shownin FIG. 3. The bed block 310 includes slots 320 that hold stationaryconventional knitting needles 330 used to knit the warp yarns toappropriate location along the width of the wire carrier. The generalsetup of the knitting machine facilitates use of an empty slot 340 ofthe weaving needle bed block 320 to guide the lock stitch wire(represented by dashed-line 350). This can be termed a “dummy needle”.The wire (350) is drawn into the overall carrier knit as it is paid outof the knitting machine. The wire can reside on a driven (or non-driven)feed roll and is fed to the carrier as it moves out of the knittingmachine. This arrangement should be clear to those of skill in the art.

Reference is now made to FIG. 4, which shows a knitted wire carrier 410according to an alternate embodiment (and constructed as describedabove), in which the compression and expansion-resisting lockstitch wire440 is located within a knit 430 adjacent to an edge of the wire weft420 of carrier 410 (i.e. in a non-centered arrangement). Thispositioning can be desirable in certain weather seal configurationswhere locating the wire closer to one side can assist in allowing theseal to bend and/or remain in place. Note that the expansion andcompression-resisting wire 440 can be located at any point along thewidth of the carrier in various embodiments so as to achieve a desiredperformance characteristic in the weather seal.

As shown in the further example of FIG. 5, the wire carrier 510 caninclude a plurality of compression and expansion-resisting wires 540 and550 knitted into appropriate knits 560 and 570, respectively, along thewidth of the wire weft 520. The placement of each wire is variable. Inthis embodiment, wires are placed on opposite sides of the overallwidth. In alternate embodiments, wires can be placed asymmetrically withrespect to the overall width—for example, one wire centered on the widthand one wire adjacent to an edge of the carrier. Again, sucharrangements of wires can depend upon desired performancecharacteristics for the weather seal and the geometry of the bends itwill experience on (e.g. the vehicle door).

The term, “wire”, as used herein to describe a compression andexpansion-resisting structure knitted (e.g. as a lockstitch) into thewire carrier should be taken broadly to include a variety of solid andmulti-filament flexible, elongated structures (cordage, etc.) capable ofbeing woven into a zig-zag wire weft, and providing desired performancecharacteristics. For example, the “wire” can be a fiberglass yarn orcord, an aramid (e.g. Kevlar®) material, a variety of solid or braidedmetals/alloys (e.g. aluminum, copper, brass, titanium, stainless steel,etc.) and/or certain polymers (e.g. monofilament polyester orpolypropylene) and/or combinations of such materials. In theillustrative embodiment, solid core low carbon steel is employed.

It should be clear that the wire carrier constructed in accordance withthe embodiments herein provides superior performance in resisting bothshort-term and long-term compression and expansion, and is relativelystraightforward to manufacture using conventional knitting machinery.

The foregoing has been a detailed description of illustrativeembodiments of the invention. Various modifications and additions can bemade without departing from the spirit and scope of this invention.Features of each of the various embodiments described above may becombined with features of other described embodiments as appropriate inorder to provide a multiplicity of feature combinations in associatednew embodiments. Furthermore, while the foregoing describes a number ofseparate embodiments of the apparatus and method of the presentinvention, what has been described herein is merely illustrative of theapplication of the principles of the present invention. For example,also as used herein, various directional and orientational terms (andgrammatical variations thereof) such as “vertical”, “horizontal”, “up”,“down”, “bottom”, “top”, “side”, “front”, “rear”, “left”, “right”,“forward”, “rearward”, and the like, are used only as relativeconventions and not as absolute orientations with respect to a fixedcoordinate system, such as the acting direction of gravity.Additionally, where the term “substantially” or “approximately” isemployed with respect to a given measurement, value or characteristic,it refers to a quantity that is within a normal operating range toachieve desired results, but that includes some variability due toinherent inaccuracy and error within the allowed tolerances (e.g. 1-2%)of the system. Accordingly, this description is meant to be taken onlyby way of example, and not to otherwise limit the scope of thisinvention.

What is claimed is:
 1. A knitted wire carrier for use in a weather seal comprising: a wire weft defining a width between edges perpendicular to an elongated length; one or more knitted warp yarns extending in the direction of the elongated length and located at one or more positions along the width of the wire weft; and at least a first compression-resisting wire knitted as a lockstitch to at least one of the warp yarns.
 2. The knitted wire carrier as set forth in claim 1 wherein the wire weft comprises a steel wire and the first compression-resisting wire comprises a steel wire.
 3. The knitted wire carrier as set forth in claim 2 wherein the wire weft defines a diameter of between approximately 0.5 and 0.91 millimeter and the first compression-resisting wire defines a diameter of between approximately 0.3 and 0.76 millimeter.
 4. The knitted wire carrier as set forth in claim 3 wherein the first compression-resisting wire defines a diameter of approximately 0.5 millimeter.
 5. The knitted wire carrier as set forth in claim 2 wherein the one or more warp yarns are constructed from a polyester material.
 6. The knitted wire carrier as set forth in claim 2 wherein the wire carrier is coated with an adhesive material that maintains the one or more warp yarns in one or more desired positions on the wire weft.
 7. The knitted wire carrier as set forth in claim 6 wherein the adhesive material comprises a latex coating.
 8. The knitted wire carrier as set forth in claim 1 further comprising at least a second compression-resisting wire knitted as a lockstitch to at least one of the warp yarns, located at a spacing along the width of the wire weft from the first compression-resisting wire.
 9. The knitted wire carrier as set forth in claim 1 wherein the first compression-resisting wire is approximately centered along the width of the wire weft.
 10. The knitted wire carrier as set forth in claim 1 wherein the first compression-resisting wire is constructed from a non-metallic material.
 11. The knitted wire carrier as set forth in claim 10 wherein the non-metallic material comprises fiberglass.
 12. A weather seal including the knitted wire carrier of claim
 1. 13. The weather seal of claim 12 constructed and arranged for attachment in at least one of a vehicle and a moisture-tight cabinet.
 14. A method for constructing a wire carrier with a knitting machine comprising the steps of: feeding and forming a wire into a wire weft having a width between edges perpendicular to an elongated length; knitting one or more warp yarns extending in the direction of the elongated length and located at one or more positions along the width of the wire weft using knitting needles in a needle bed; and feeding a first compression-resisting wire as a lockstitch to at least one of the one or more warp yarns.
 15. The method as set forth in claim 14 wherein the step of feeding the first compression-resisting wire with the needle bed as a dummy needle.
 16. The method as set forth in claim 14 further comprising applying an adhesive coating to the wire carrier to maintain the one or more warp yarns in position of the wire weft.
 17. A wire carrier made by the process of: feeding and forming a wire into a wire weft having a width between edges perpendicular to an elongated length; knitting one or more warp yarns extending in the direction of the elongated length and located at one or more positions along the width of the wire weft using knitting needles in a needle bed; and feeding a first compression-resisting wire as a lockstitch to at least one of the one or more warp yarns. 